I don't know what state or location you are in, but as far as charging money for products and being a business goes, you can typically register a DBA for under $20 or $30 with your local county clerk's office. With that you can open a business account with your local bank and use PayPal as your payment method for products if you choose to sell anything. You would just list all income on a Schedule C when you file your taxes should you make more than $600 in a year. So the start-up as an actual business may not be that bad in your area if your in the states, but you would need to check into that a bit more as time goes along.
As to the product. With great artwork and layout there could be some potential for it but it might work better as a freebie to go along with some other form of product. Now if the fields are all editable and people can go in and change stat names, any listed skills, and type into it themselves as well, it would greatly increase its marketability.
As far as any other product goes, as a fellow pointed out on a blog I read sometime back (sadly I can't remember which one or I would link to the posting) making a niche product you enjoy developing and selling it as PDF and print on demand and you will likely make as much or more than most people who write freelance for game companies. I definitely look forward to seeing what you come up with!

As to Scaling, the samples we use in Mini Six are as follows:
Character/Animals = no modifier
Air Cycle, Car, Little Dragon, Wagon = +2D
Big Dragon, Galley, Mecha, Tank = +4D
Fighter, Light Transport, Heavy Mecha = +6D
Capital Ship, Elder God, Space Station = +12D
Mega Space Station, Planets = +24D
These work pretty well for us and might help inspire you in coming up with your own classifications for your scaling system. There are a few other sample categories systems floating around here on the forums too I think.

As I do the typing to bring an earlier set of magic notes I recently found from hard copy back to digital copy (the old hard drive these notes are from died like 6 years ago) I had an errant thought about the disconnect between supernatural attributes and the normal array in OpenD6.
In the Simple Magic System we put into Mini Six we made Magic a skill under Wit. In D6 Fantasy and many other games, Magic is split out as a 7th attribute with magic skills under that. Now I do also like this method as the deminished other attributes works as a balance against the power of magic. For reference on this balancing aspect look at a beginning Jedi character in Star Wars Expanded and Revised with all three force skills vs. a Bounty Hunter for combat abilities. However, when you split it out as a 7th attribute you can be dumb but powerful in magic.
By the rules a character could easily spend their 18D in starting dice as follows:
Strength 4D
Dexterity 4D
Intellect 1D
Awareness 3D
Presence 2D
Craft 1D
Magic 3D
This makes for a magic using character, who is an idiot in all things scholarly but can still access the arcane arts of the universe. In many fantasy games this really does not fit a good archetype.
Also, do you limit Magic or similar paranormal abilties to only 3D at character creation or can the player spend 4D in it (or whatever your highest dice allowed is) so they can "max" out their magic.
What do you think of limiting the Magic Attribute to be no higher than the character's Intellect/Knowledge/Wit attribute at character creation? Basically to have 3D in Magic you would need to bump that Intellect up to at least 3D as well. Would this be something you would consider in your games? Have you ever seen people do this sort of oddity with their magic/paranormal abilities outside the classic Jedi examples?
I am just curious so I thought I would ask my mates here.

Very true on participation man. I found some old notes I had for a collection of magic spells for a magic system conversion of sorts from my pre Mini Six efforts. I plan on polishing them up just a wee bit and sharing them. Also thinking of plugging it into a simple, brief fantasy scenario. Hopefully try and get a wee bit of sword and sorcery tinted pulp for enjoyment. No promises on quality or timeline, but we do need to remind people that OpenD6 is around to be played with.

First let me say, these are a great idea man and very well done. I have been gone from the forum far too long to have missed this very clever idea on your part. I look forward to seeing what other ones you come up with.
On the issue of fonts, some fonts out on the web are designed to not be allowed to be embedded into PDFs. The great fonts on the HP Lovecraft Society sadly fall into this category. That may be the problem you are running into on them.

Just to offer up my few coppers worth of thoughts, if wanting to go for a pseudo-class option of sorts, on the templates put in a short list of skills that are easier for those of that template to accomplish - instead of charging others more for the skill to make it special for that template, just state that all difficulties are reduced by one level when attempted by that template. The only skills I would exclude are the combat based ones. Knights would have skills like Riding, Endurance, and Heraldry as an option for them.
Another option is to go with special advantages that are unique to certain templates and cannot be gained by others.
Just a few idol thoughts on it. Good luck with the setting mate!

Fantasy is always the biggest hit for RPGs. Maybe because D&D was first, maybe because we all love knights and wizards and tales of daring due. The hardest part of fantasy is coming up with something both different enough to attract attention while also staying close enough to the roots of the common tropes of the genre that it isn't seen as too niche. But I am coming to the conclusion that the easiest way to do it is to simply develop a setting you like and really have a passion about. That passion will show through and if it is done well, it will develop an attraction.
I also love the idea of a good sci-fi setting. The thing with Sci-Fi is that D6 started out there. Star Wars and by extension Space Opera is what our beloved system was built upon. What makes many sad is that we can't continue to develop that line under the original IP anymore. But to me that is okay. Because when you listen to many talk about it, there were as many of us playing a version of Traveller as there were noble rebels fighting the good fight. In my own doodlings on Mini Six I have toyed with attempting to develop a mini setting involving the United Planetary Alliance made up of hundreds of races under one common banner who send out ships of exploration and defense to find new worlds and seek out new civilizations, bravely traveling where no sentient has gone before.
What type of sci-fi to go for in the end though? I kind of like the idea of the Traveller model to some degree. A broad sandbox of options. You can be smugglers and traders skirting along the Outer Rim trying to make your way without to much involvement from the Core Worlds. Maybe you prefer a more militant game and take on the roll of fighter pilots along the Border fending off aliens who prefer to conquer instead of ally with the Galactic Confederation while also trying to stop pirates and smugglers from stealing supplies needed desperately on isolated worlds. Or perhaps you think a game of noble intrigue is preferred and everyone takes on the position of Founding House of the Core Worlds. Finding themselves entwined in politics and plotting in a world of stratified nobility under a vineer of civilized formality that hides treacherous savagery. And if you want a mystic order of knights or prophets with access to powers few still understand, well that could easily be built into it as well.
The thing is I guess, I love our little sand box and tool kit, you can really do all sorts of fun things with the Open-D6 rules. I would love to see some more ideas developed by people and find out what new and interesting things they can come up with.
Sorry to have rambled on here. I can tend to wax on a bit about all the things I can easily see being done with Open-D6.
I recently moved and when I did I found notes my friends and I came up with for a strange little fantasy game using the old Star Wars rules from like 9 years ago. It featured races like wolfmen and minotaurs set against a vaguely viking culture and environment while adapting the old Force Rules to use as the foundations of the magic system. Just made me remember again how nice and flexible our beloved system is.